1996 BMW 323i starter motor

Fig
.
16
.
Multimeter
or
Digital
Volt/Ohmmeter
(DVOM)
.

BMW
Special
Tools

FUNDAMENTALS
FOR
THE
DO-ITYOURSELF
OWNER
010-11

0012223

Some
of
the
more
challenging
repairs
covered
in
this
manual

cal¡
for
the
use
of
BMW
special
tools
.
This,
however,
does
not

automatically
mean
that
thejob
is
too
complicated
or
out
of

reach
of
thenovice
.

Many
of
the
BMW
special
tools
mentioned
in
this
manual
are
simplythe
best
thing
to
use
to
do
thejob
correctly
.
In
these
cas-

es,
the
tool
is
identified
with
a
BMW
part
number
.
See
your
au-

thorized
BMW
dealer
parts
department
for
information
on
how

to
order
special
tools
.

There
are
some
jobs
for
which
expensive
special
tools
are

essential,
and
not
a
cost-effective
purchase
for
one-time
repair

by
the
do-it-yourself
owner
.
This
manual
includes
such
repairs

for
the
benefit
of
these
with
the
necessary
experience
and
ac-

cess
to
tools
.
For
the
do-it-yourselfer,
the
need
for
special
tools

is
noted
in
the
text,
and
whether
or
not
BMW
dealer
service
is

recommended
.

EMERGENCIES

Changing
a
Tire

Stop
thecar
onas
flat
a
surface
as
possible,
in
a
place
where

you
canbe
easily
seen
by
other
drivers
.
Avoid
stopping
just

over
the
crest
of
a
hill
.
Turnon
the
emergency
flashers,
and
set

out
(lares
or
emergency
markers
well
behindthecar
.
Chock
the

wheel
(wheel
chock
located
in
trunk)
diagonally
opposite
to
the
one
being
changed
.
Passengers
shouldgetout
of
thecar
and

stand
well
away
from
the
road
.
Remove
the
spare
tire
from
the
spare
tire
storage
tray,
as
described
later
.

WARNING
-

If
a
tire
goes
fíat
while
drtving,
pull
well
off
the
road
.
Changing
a
tire
ona
busy
street
or
highway
is
very
dangerous
.
If
necessary,
drive
a
short
distance
on
the
fíat
tire
to
get
to
a
sale
place
.
tt
is
much
better
to
ruin
a
tire
or
rim
than
to
risk
being
hit
.

Take
the
jack
and
tools
from
the
tool
area
beneath
the
trunk

mat
.
Remove
the
spare
tire
from
the
tire
storage
tray
.

Loosen
the
wheel
bolts
while
the
car
is
on
the
ground,
but

leave
them
a
little
snug
.
Placethe
jack
in
the
lifting
point
nearest

the
wheel
beingchanged,
lifting
points
are
shown
in
Fig
.
1
and

Fig
.
2)
.
Use
a
board
to
provide
a
firm
footing
for
the
jack
if
the

ground
is
soft
.
Raise
the
car
only
lar
enough
so
that
the
wheel
is

fully
off
the
ground
and
then
remove
the
wheel
nuts
and
the

wheel
.

Insta¡¡
the
spare
wheel
.
Install
the
wheel
nuts
and
tighten

them
by
hand,
then
lower
the
car
.
With
all
wheelson
the

ground,
fully
tighten
the
nuts
in
a
crisscross
pattern
.
Torque
the

wheel
nuts
when
installing
the
wheel
.
Check
the
inflation
pres-

sure
of
the
spare
tire
.

Tightening
torques

"
Wheel
to
wheel
hub
.....
100
t
10
Nm
(74
t
7
ft-Ib)

Car
Will
Not
Start

If
the
engine
tucos
over
slowly
or
not
at
all,
especially
on
cold

mornings,
the
battery
may
not
be
sufficiently
charged
.
Jump-

starting
the
battery
from
another
car
may
help
.

WARNING
-

On
carswith
manual
transmisston,
push
starting
(or

tow
starting)
acar
ts
not
recommended
by
BMW
.

NOTE-

Be
sure
to
read
the
cautions
underJump
Starting
Car
prior
boosting
a
low
battery
.
Fatlure
to
followthe
cau-

tions
may
result
in
damage
to
the
electronic
compo-
nents
in
the
car
.

If
the
engine
is
turning
over
at
normal
speed
with
the
starter

motor,
the
battery
and
starter
are
fine
.
Check
to
make
sure
that

there
is
fuel
in
the
tank
.
Do
not
rely
on
the
fuel
gauge,
it
may
be

faulty
.
Instead,
remove
the
gas
filler
cap
and
rock
thecar
.
If

there
is
gas
in
the
tank,
you
should
hear
a
sloshing
sound
at
the

filler
neck
.
lf
there
is
plenty
offuel
in
the
tank,
see100
Engine-

General
for
in-depth
diagnostics
and
troubleshootingproce-

dures
.

EMERGENCIES

Camshaft
installation
waíting
times

"
Ator
above
68°F
(20°C)
............
.
..
10
minutes

"
50-68°F
(10-20°C)
................
..
.
30
minutes

"
32-50°F
(0-10°C)
.
.......
.
.........
..
.
75minutes
"
Reinstall
timing
chain
sprockets
and
tensioner
as
spe-

cifically
described
in
117
Camshaft
Timing
Chain
.



i

"
Wait
at
least
10minutes
before
cranking
engine
over

with
starter
motor
for
the
fi+



1
1/
/~~
.0
time
.

Tightening
Torques

"
Camshaft
bearing
caps

to
cylinder
head
(M7)
.............
15
Nm
(11
ft-Ib)

"
Cylinder
head
cover

to
cylinder
head
(M6)
.............
10
Nm
(89
in-lb)

"
Primary
timing
chain
tensioner
plug

to
cylinder
head
..
..
..
...........
40
Nm
(30
ft-Ib)

(see
117
Camshaft
Timing
Chain)

"
Spark
plugs
(M12)
..
.
.............
23
Nm
(17
ft-Ib

"
Timing
chain
cover
(upper)

to
cylinder
head
..
.
.
...
..........
10
Nm
(89
in-lb)

"
Timing
chainsprockets
to
camshaft

M6
........
.
...
.
..
.



..........
10
Nm
(7.5
ft-Ib)

M7



............
.
..
..
...........
15
Nm
(11
ft
.lb)

(see
117
Camshaft
Timing
Chain)

Camshafts,
removing
and
installing

(M44
engine)

Special
BMW
service
tools
should
always
be
used
to
remove

and
install
the
camshafts
.
Removal
and
installation
of
the
cam-

shafts
without
the
special
tools
can
result
in
camshaft
and
val-

vetrain
damage
.

1.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this

manual
on
page
vi¡¡
.

CYLINDER
HEAD
AND
VALVETRAIN



116-
3

2
.
Remove
spark
plugs
.
See
1201gnition
System
.

3
.
Rotateengine
until
a
pair
of
camshaft
lobes
are
point-
ing
up
.
Using
BMW
special
tool
115
130,
depresseach
valve
and
valve
spring
enough
to
remove
rocker
arms
.

Rotate
engine
for
the
next
pair
of
rocker
arms
.
See
Fig
.

3
.

cover
.

Fig
.
3
.



BMW
special
tool
no
.
11
5130
(arrow)
being
used
to
depress
valve
stem
to
remove
rocker
arm
.

WARNING
-

Removed
rocker
arms
must
be
reinstalled
in
the
same
locations
.

4
.
Remove
primary
timing
chain
tensioner
from
right
side

of
cylinder
head
.

The
camshafts
can
be
removed
with
the
cylinder
head



5
.
Remove
upper
timing
chaincover
.

mounted
onthe
engine
.
The
first
step
is
to
remove
the
cylinder

head
cover
.
See
113
Cylinder
HeadRemoval
and
Installa-



NOTE-

tion
.



lt
is
not
necessary
to
remove
the
lower
timing
chain

6
.
Remove
timing
chain
sprockets
with
timing
chains
from

front
of
camshafts
.
See
117
Camshaft
Timing
Chain
.

Remove
upper
timing
chain
guide
from
cylinder
head
.

WARNING-



7
.
Remove
camshaft
bearing
caes
and
remove
cam
The
process
of
evenly
loosening
the
camshaft
bear-



shafts
.
ing
cap
nuts
is
NOT
an
acceptable
method
of
re-

moving
the
camshafts
.
Be
sure
to
read
the



CAUTION-
procedure
through
before
starting
the
job
.
Camshaft
bearing
capsmust
be
reinstalled
intheir

original
locations
.

CYLINDER
HEAD,
DISASSEMBLYAND
ASSEMBLY

116-
6



CYLINDER
HEAD
AND
VALVETRAIN

9
.
Camshaft
installation
is
reverse
of
removal,noting
the

following
:

"
Prior
to
installation,
check
al¡
components
for
wear
as
described
below
under
Cylinder
Head
and
Val-

vetrain
Reconditioning
.

"
Crankshaft
must
be
at
least
45°
away
from
MC
before

installing
camshafts
to
cylinder
head
.

"
Lubricate
camshafts
prior
to
installation
.
"
Insta¡¡
camshafts
into
cylinder
head
with
lobes
for
cyl-
inder
no
.
1
pointing
up
and
towards
each
other
.
See
Fig
.
8
.

"
After
installing
camshaft(s),
observe
specified
waiting

time
for
hydraulic
cam
followers
to
fully
compress
be-

fore
bringing
crankshaft
back
to
TDC
.

Fig
.
8
.



Camshaft
correctly
positioned
for
reassembly
so
thatcylinder
no
.
1
lobes
(arrows)
face
each
other
.

Tightening
Torques

"
Camshaft
bearing
caps
to
cylinder
head
(M7)
.
..
...
..
.
....
15
Nm
(11
ft-Ib)
"
Cylinder
head
cover
to
cylinder
head
(M6)
..
.
..........
10
Nm
(89
in-lb)

"
Primary
timing
chaintensioner
to
cylinder
head-see
117
Camshaft
Timing
Chain
"
Spark
plugs
(M12)
.............
.
.
23
Nm
(17
ft-Ib)

"
Timing
chain
sprocket
to
camshaft
flange
(M6)-see
117
Camshaft
Timing
Chain

CYLINDER
HEAD,
DISASSEMBLYAND
ASSEMBLY

Valves,
removing
and
installing

1
.
Remove
cylinder
head
as
described
in
113
Cylinder

HeadRemoval
and
Installation
.
Remove
exhaust

manifold(s)
.

2
.
Remove
camshafts
using
special
tools
as
descríbed

earlier
.

3
.
On
M42
and
al¡
6-cylinder
engines
:
Remove
camshaft

carriers
by
pulling
them
straight
up
off
mounting
studs
.

CAUTION-

"
Do
not
let
the
hydraulic
cam
followers
fa¡¡
out
as
the
camshaft
carrier
is
removed
.
Special
suction
cupsare
available
from
BMW
to
hold
the
hydrau-
lic
cam
followers
in
place
during
carrier
removal
.
Camshaft
installation
waiting
times

"
at
or
above
68°F
(20
0
C)
....
..
.
..
......
10
minutes

"
50-68°F
(10-20°C)
...
.
..
....
.
..
......
30
minutes

"
32-50°F
(0-10°C)
....
.
..
....
.
..
......
75
minutes
4
.
On
M44
engines
:
Remove
all
hydraulic
valve
adjusters
.
See
Hydraulicvalve
adjusters,
checking
and
re-
"
Reinstall
timing
chainsprockets
and
tensioner
as
spe-



placing
(M44
engine),
later
in
this
section
.
cifically
described
in
117
Camshaft
Timing
Chain
.
"
Waít
at
least
10
minutes
before
cranking
engine
over



CAUTION-
withstarter
motor
for
the
first
time
.



Hydraulic
valve
adjusters
should
be
stored
in
an
upright
position
.
lf
necessary,
use
amagnetic
tool
to
aid
in
removal
of
the
adjusters
.

"
Hydraulic
cam
followers
shouldbe
stored
in
an
upright
position
.

5
.
Remove
valves
using
a
valve
spring
compressor
.

NOTE-

"
The
M44
cylinder
head
has
recessed
valve
stems
.
This
requires
the
use
of
a
special
valve
spring
com-
pressor
tool
.

"
Label
each
valve
assembly
as
it
is
removed
so
it
can
be
installed
in
its
original
position
.

6
.
Remove
and
discard
valve
stem
oil
seals
from
valve
guides
.
See
Valve
stem
oil
seals
later
in
this
section
.

7
.
Valve
installation
is
reverse
of
removal
.

"
Reinstall
exhaust
manifold(s)
with
new
gaskets
.
Use
Molycote
HSC'
5
or
equivalent
anti-seize
thread
com-
pound
on
fasteners
.

Tightening
Torque

"
Exhaust
manifold
to
cylinder
head
M7
............
..
...
....
.
...
..
20
Nm
(15
ft-Ib)

CHARGING
SYSTEM

TROUBLESHOOTING
.............
.
.
.
.
.121-2

Charging
System
Quick-Check
...
.
..
.
...
.
121-2

Static
current
draw,
checking
........
.
...
.
121-2

BATTERY
SERVICE
....................
121-3

Battery
Testing
.
.
.
.
.
.........
.
........
.
121-3

Hydrometer
Testing
.
...
.
.
.
...
.
.........
121-3

Battery
Open-Circuit
Voltage
Test
....
.
....
121-4

Battery
Load
Voltage
Test
.
.
.
.
.
.
.........
121-4

Battery
Charging
.
.
.
.
...
.
.
.
.
.
.
.
.........
121-4

ALTERNATOR
SERVICE
.
.
.
.
.
.
.....
.
...
121-4

Chargingsystem,checking
.
.
.
.
.
.........
121-4

Alternator,
removingand
installing

(4-cylinder
engine)
....
.
.
.
.
.
.
.
.........
121-5

Alternator,
removingand
installing

(6-cylinder
engine)
..
.
.
.
.
.
.
.
.
.
.........
121-6

GENERAL

The
charging
system
consists
of
a
belt-driven
alternator

with
integral
voltage
regulator
and
a
battery
mounted
in
the

luggage
compartment
.

Various
versions
of
alternators,
voltage
regulators,
starters,

and
batteries
are
used
in
the
E36
cars
.
It
is
important
to
re-

place
components
according
tothe
original
equipment
speci-

fication
.
Check
with
an
authorized
BMW
dealer
for
specific

application
and
parts
information
.

WARNING
-

"
Weargoggles,
rubbergloves,
and
a
rubberapron
when
working
around
batteries
and
battery
acid
(electrolyte)
.

"
Battery
acid
contains
sulfuric
acid
and
can
cause
skin
irritation
and
burning
.
ff
acid
is
spilled
onyour
skin
or
clothing,
flush
the
area
at
once
with
large
quantities
of
water
.
lf
electrolyte
gets
into
your
eyes,flush
them
with
largequantities
of
clean
wa-
terfor
several
minutes
and
call
a
physician
.

"
Batteries
that
are
being
charged
or
are
fully
charged
give
off
explosive
hydrogen
gas
.
Keep
sparks
and
open
flames
away
.
Do
not
smoke
.

BATTERY,
STARTER,
ALTERNATOR



121-1

121
Battery,
Starter,
Alternator

GENERAL
..
.
...
.
........
.
...
.
.
.
.
.
.
.
.
.
121-1



Voltage
regulator,
removing
and
ínstalling
.
.
.
121-6

Alternator
brushes,
inspecting
and
replacing
.121-7

STARTER
SERVICE
....
.
.
.
.
.
..........
.121-7

Starter
Troubleshootíng



121-7



15
..
.
.
.
.
.
........
.
.
.

Starter,
removing
and
installing

(4-cylinder
engine)
....
.
.
.
............
.
121-8

Starter,
removing
and
installing

(6-cylinder
engine
with
manual
transmission)
..
.
...........
.
...
121-8

Starter,
removing
and
installing

(6-cylinder
engine
with

automatic
transmission)
................
121-9

Solenoid
switch,
removingand
installing
....
121-10

TABLES

a
.
Battery,
Starter
and
Charging
System

Troubleshooting
............
.
.
.
.
:...
........
121-2

b
.
Specific
Gravity
of
Battery
Electrolyte
at
80°F
(27°C)
...............
.
.
..
..........
121-3

c
.
Open-Circuit
Voltage
and
Battery
Charge
........
121-4

d
.
Battery
Load
Test-Minimum
Voltage
.
..........
121-4

CAUTION
-

"
Prior
to
disconnectiog
the
battery,
read
the
bat-tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
"
Disconnecting
the
battery
cables
may
erase
fault
codes
stored
in
control
unit
memory
.

"
Always
disconnect
the
negative
()
battery
cable
first
and
reconnect
it
last
.
Cover
the
battery
post
with
an
insulating
material
whenever
the
cable
is
removed
.

"
After
reconnecting
the
battery,
the
power
window
motors
must
be
reinitialized
.
See
511
Door
Win-
dows
.

"
Never
reverse
the
battery
cables
.
Even
a
momen-
tary
wrong
connection
can
damage
the
alternatoror
other
electrical
components
.

"
Battery
cables
may
be
the
same
color
.
Label
ca-blebefore
removing
.

GENERAL

121-2



BATTERY,
STARTER,
ALTERNATOR

CHARGING
SYSTEM
TROUBLESHOOTING



Static
currentdraw,
checking

Charging
system
diagnostics
requires
special
test
equip-

ment
.
If
the
test
equipment
is
not
available,
charging
system

fault
diagnosis
can
be
performedby
an
authorized
BMW
deal-

eror
other
qualified
repair
shop
.
A
general
troubleshooting

guide
is
given
in
Table
a
.

Charging
System
Quick-Check

As
a
quick-check,
use
a
digital
multimeter
lo
measure
volt-



2
.
Disconnect
battery
negative
(-)
cable
.

age
across
the
battery
terminals
with
the
key
off
and
then

again
with
the
engine
running
.
The
battery
voltage
should
be



CAUTION-
about12
.6
volts
with
key
off
and
approximately
14
.0
volts
with



Prior
to
disconnecting
the
battery,
read
the
battery
the
engine
running
.
If
the
voltage
does
not
increase
when
the



disconnection
cautions
given
at
the
front
of
this
engine
is
running,there
is
a
fault
in
the
charging
system
.



manual
onpaga
viii
.

NOTE
-

The
regulated
voltage
(engine
running)
should
be
be-
tween
13
.5
and
14
.5,
depending
on
temperatura
and
operating
conditions
.
If
the
voltage
is
higher
than
14
.8,
the
voltage
regulator
is
most
Mely
faulty
.

Check
for
clean
and
tight
battery
cables
.
Check
the
ground

cable
running
from
the
negative
(-)
battery
terminal
lo
the

chassis
and
the
ground
cable
running
from
the
engine
lo
the

chassis
.
Check
the
alternator
drive
belt
condition
and
tension
.

If
the
battery
discharges
over
time,
there
may
be
a
constant

drain
or
current
draw
on
the
battery
.
A
small
static
drain
on
the

battery
is
normal,
but
a
largedrain
will
cause
the
battery
lo

quickly
discharge
.
Make
a
static
current
draw
test
asthe
first

step
when
experiencing
battery
discharge
.

1
.
Make
sure
ignition
and
al¡
electrical
accessories
are

switched
off
.

3
.
Connect
a
digital
ammeter
between
negative
battery

post
and
negative
battery
cable
lo
measure
current
.

See
Fig
.
1
.
Wait
at
least
one
minuta
lo
get
an
accurate

reading
.

A
range
of
about
0
lo
100
milliamps
is
normal,
dependingon

the
number
of
accessories
that
need
constant
power
.
A
current

of
400
milliamps
(0.4
amp)
or
more
may
indicate
a
problem
.

Table
a
.
Battery,
Starter
and
Charging
System
Troubleshooting

Symptom



1



Probable
Cause



1



Correctiva
Action

1
.
Engine
cranks
slowlyor
not



a
.
Battery
cables
loose,
dirty
orcor-



a
.
Clean
or
replace
cables
.
See020
Maintenance
Program
.
a
tall,
solenoíd
clicks
when



roded
.
starter
is
operated
.



b
.
Battery
discharged
.



b
.
Charge
battery,
test
and
replace
if
necessary
.
c
.
Body
ground
straploose,
dirty
or



c
.
Inspect
ground
strap,
clean,
tighten
or
replace
if
necessary
.
corroded
.
d
.
Poor
connection
at
starter
motor



d
.
Check
connections,
test
for
voltage
at
starter
.
Test
for
voltage
at
terminal
30
.



neutral
safety
or
clutch
interlock
switch
.
e
.
Starter
motor
or
solenoid
faulty
.



e
.
Test
starter
.

2
.
Battery
will
not
stay



a
.
Short
circuit
draining
the
battery
.



a
.
Test
for
excessive
current
drainwith
everything
electrical
in
the
charged
more
than
a
few



vehicle
off
.
days
.



b
.
Short
driving
trips
and
high
elec-



b
.
Evaluate
driving
style
.
Where
possible,
reduce
electrical
con
trical
drain
on
charging
system



sumption
when
making
short
trips
.
does
not
allow
battery
to
re-
charge
.
c
.
Drive
belt(s)
worn
or
damaged
.



c
.
Inspect
or
replace
multi-ribbed
belt(s)
.
See
020
Maintenance
Program
.
d
.
Battery
faulty
.



d
.
Test
battery
and
replace
íf
necessary
.
e
.
Battery
cables
loose,
dirty
orcor-



e
.
Clean
or
replace
cables
.
See
020
Maintenance
Program
.
rodad
.
f
.
Alternatoror
voltage
regulator



f
.
Test
alternator
and
voltage
regulator
.
faulty
.

3
.
Battery
losing
water
.



1
a
.
Battery
overcharging
.



1
a
.
Test
voltage
regulator
for
proper
operation
.

4
.
Lights
dim,
light
intensity



a
.
Drive
belt(s)
worn
or
damaged
.



a
.
Inspect
or
replace
multi-ribbed
belt(s)
.
See
020
Maintenance
varies
with
engine
speed
.



Program
.
b
.
Alternatoror
voltage
regulator



b
.
Test
alternator
and
voltage
regulator
.
faulty
.
c
.
Body
ground
straps
loose,
dirty
or



c
.
Inspect
ground
straps,
clean,
tighten
or
replace
as
necessary
.
corroded
.

CHARGING
SYSTEM
TROUBLESHOOTING

Alternator
brushes,



STARTER
SERVICE
inspecting
and
replacing

Regulator
brushesarenot
available
as
replacement
parts
from
BMW
.
Replacement
brushes
may
be
available
from
af-

termarket
sources,
however
.

1
.
Remove
voltage
regulator
as
described
above
.

2
.
Clean
brush
contact
sürfaces
and
measure
brush
pro-trusion
.
See
Fig
.
7
.

Check
for
battery
voltage
at
terminal
50
of
the
starter
motor
Fig
.
7
.



Regulator
brush
protrusion
(A)
.



with
the
key
in
the
start
position
.
See
Fig
.
8
.
If
voltage
is
not
present,
check
the
wiring
between
the
ignition
switch
and
the
starter
terminal
.
If
voltage
is
present
and
no
other
visible
wir
Voltage
Regulator



ing
faults
can
be
found,
the
problem
is
most
likely
interna¡in

"
Brush
protrusion
(minimum)
.......
.
..
5
mm
(
1
/4
in
.)



the
starter
motor
.

3
.
To
replace
brushes,
carefully
and
as
quickly
as
possi-

ble,
unsolder
brush
lead
from
brush
holder
termina¡,

withdrawing
brush
from
holder
at
same
time
.

4
.
Remove
any
traces
of
solder
frombrush
holder
termi-
nal
using
solder
wick
.

5
.
Fit
spring
into
brush
holder
and
inserí
new
brush
.

6
.
Guide
brush
lead
into
terminal
and
solder
into
place
.

Check
for
free
movement
of
brushes
when
solder

cools
.

7
.
Check
brush
slip
rings
in
alternator
for
wear
.
Lightly
clean
slip
rings
using
fine
abrasive
cloth
.

BATTERY,
STARTER,
ALTERNATOR



121-
7

Starter
Troubleshooting

If
the
starter
tucos
the
engine
slowlyor
fails
to
operate
when
the
ignition
isin
the
start
position,
check
the
battery
first
.
In-
spect
the
starter
wires,
terminals,
and
ground
connections
for
good
contact
.
In
particular,
make
sure
the
ground
connections
between
the
battery,
the
body
and
the
engine
are
completely
clean
and
tight
.
If
no
faults
can
be
found,
the
starter
may
be
faulty
and
should
be
replaced
.

NOTE
-

"
Starting
in1194,
a
factory-installed
drive-away
protec-
tion
system,
alsoreferred
to
as
EWS
or
EWS
11,
was
used
on
all
E36
cars
.
This
system
prevenís
operation
of
the
starter
when
the
system
is
engaged
.
See
515
Central
Locking
and
Anti-theft
.

"
On
cars
with
automatic
transmission,
a
starter
relay
and
a
neutral
safetyswitchare
used
to
present
theen-
ginefrom
starting
in
gear
positions
other
than
park
or
neutral
.
ff
voltage
is
not
present
atterminal
50
with
the
key
in
the
startposition,
check
these
components

To
make
the
most
accurate
check
of
the
battery
cables
and
starterwiring,
make
a
voltage
drop
test
on
the
cables
and
wir-

ing
as
described
in
600
Electrical
System-General
.

Terminal
30
'
\



/
Terminal
30h

0012518

8
.
Reinstall
regulator
and
alternator
.



Fig
.
8
.



Typical
starterwiring
terminal
identification
.
Large
wireat
ter-
minal
30
is
direct
battery
voltage
.
Smaller
wire
at
terminal
50
operates
starter
solenoid
via
ignition
switch
.

STARTER
SERVICE

121-
8



BATTERY,
STARTER,
ALTERNATOR

1f
the
solenoid
audibly
cliicks
but
the
motor
does
not
turn,



Starter,
removing
and
installing
switch
on
the
lights
andtum
the
key
to
the
start
position
.
lf
the



(6-cylinder
engine
with
lights
go
out
while
attempting
to
start,
the
battery
cable
may
be



manual
transmission)
loose
or
the
starter
may
have
a
short
circuit
.
If
the
lights
stay

on,the
solenoid
is
most
likely
atfault
.
The
starter
on
a
6-cylinder
car
with
manual
transmission
is

Starter,
removing
and
installing

(4-cylinder
engine)



1
.
Disconnect
negative
(-)
battery
cable
.

1
.
Disconnect
negative
(-)
cable
from
battery
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery

disconnection
cautions
given
at
the
front
of
this

manual
on
page
viii
.

2
.
Remove
guide
tube
for
oil
dipstick
.

3
.
Raise
vehicle
.

WARNING
-

Make
sure
the
car
ís
stable
and
wefl
supported
at
all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
forthe
purpose
.
A
floor
jack
is
not
adequate
support
.

4
.
Disconnect
wiring
from
starter
.

5
.
Remove
top
and
bottom
starter
bolts
.
Bottom
bolt
must

be
removed
from
below
car
.
Remove
starter
support

bracket,
if
applicable
.

removed
from
below
.

2
.
Raise
vehicle
.

3
.
Remove
reinforcing
cross
bracefromunder
transmís-

sion,
if
applicable
.

4
.
Remove
cover
from
fuel
filter
and
fuel
lines
on
left
side

underneath
car,
if
applicable
.
Detach
fuel
lines
and
har-

ness
connectors
from
retainingbrackets,
as
necessary

5
.
Disconnect
wiring
from
starter
.

6
.
Loosen
andremove
bolts
and
nuts
fastening
starter
to

transmission
bell
housing
and/or
engine
block
.
Remove

starter
supportbracket
.

7
.
Remove
starter
from
below
.

8
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-

age
.

9
.
Installation
is
reverse
of
removal
.

6
.
Pull
starter
downward
and
turn
until
solenoid
is
at
top,



Tightening
Torques

then
remove
from
car
.



"
Re¡
nforcing
cross
brace

to
chassis
(M10)
..
...............
42
Nm
(31
ft-Ib)

7
.
>Check
starter
pinion
gear
and
flywheel
teeth
for
dam-



"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)

age
.



"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)

"
Support
bracket

8
.
Installation
is
reverse
of
removal
.



to
engine
block
(M10
bolt)
.........
47
Nm
(35
ft-Ib)

"
Wire
to
terminal
50
(M6
nut)
.........
6
Nm
(53
ín-Ib)

"
Wire
to
terminal
30
(M8
nut)
.........
12
Nm
(9
ft-lb)

Tightening
Torques

"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-lb)

Wire
to
terminal
50
(M6
nut)
........
6
Nm
(53
in-lb)

"
Wire
toterminal
30
(M8
nut)
...
,
..:.
12
Nm
(9
ft-Ib)

STARTER
SERVICE

121-1
O



BATTERY,
STARTER,
ALTERNATOR

9
.
Remove
starter
from
above
.

10
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
age
.

11
.
Installation
is
reverse
of
removal
.

Tightening
Torques

"
tntakemanifold
to
cylinder
head

M7
nut
...
.
................
...
.
15
Nm
(11
ft-Ib)

M8
nut/bolt
.............
.
.
..
...
22
Nm
(16
ft-Ib)

"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)

"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)

"
Support
bracket

to
engine
block
(M10
bolt)
.
.
..
..
...
47
Nm
(35
ft-Ib)

"
Wire
toterminal
50
(M6
nut)
.
..
.....
6
Nm
(53
in-lb)

"
Wire
toterminal
30
(M8
nut)
...
.....
12
Nm
(9
ft-Ib)

Solenoid
switch,
removing
and
installing

1
.
Remove
starter
as
described
above
.
Tightening
Torque

2
.
Remove
cover
from
solenoid
switch
.



"
Field
winding
strap
to
starter
(M8)
...
.
12
Nm
(9
ft-Ib)

3
.
Disconnect
fieid
winding
strap
between
starter
motor

and
solenoid
switch
.

NOTE-

The
condition
of
the
field
winding
strap
is
critical
.
If
it
is
damaged,
bumed
or
partially
melted
through,
a
new
or

rebuilt
starter
motor
is
needed
.

4
.
Remove
solenoidswitch
mounting
screws,
and
sepa-

,
rate
solenoid
from
starter
.
See
Fig
.
12
.

CAUTION-

When
installing
fieid
winding
strap
to
starter,
posi-

tion
it
so
that
it
does
not
contact
the
starter
body
.

STARTER
SERVICE

131~184

Fig
.
12
.
Starter
solenoid
mounting
screws
(arrows)
are
tight
.
Use
en
impact
screwdriver
to
loosen
the
screws
.

5
.
Installation
is
reverse
of
removal
.
Lubricate
solenoid
pistos
with
light
grease
.